23LA01 – Potential Risk of Vehicle Fire – 2022 Lexus NX450h+

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July 12, 2023 NHTSA CAMPAIGN NUMBER: 23V478000

DC-DC Converter May Fail and Short Circuit

A short circuit can cause the DC-DC converter to overheat, increasing the risk of a vehicle fire.

 

NHTSA Campaign Number: 23V478

Manufacturer Toyota Motor Engineering & Manufacturing

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 43,442

 

Summary

Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain 2021-2022 RAV4 Prime and 2022 Lexus NX450h+ plug-in hybrid electric (PHEV) vehicles. The electric current rectifying module contained within the DC-DC converter may have been damaged during production, which can result in an electrical short-circuit.

 

Remedy

Owners are advised not to charge their vehicles when the ambient air temperature is below or expected to drop below 41 degrees Fahrenheit (5 degrees Celsius). Dealers will replace the DC-DC converter, free of charge. Owner notification letters are expected to be mailed August 7, 2023. Owners may contact Toyota’s customer service at 1-800-331-4331. Toyota’s number for this recall is 23TB07/23LB01.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


SAFETY RECALL 23LA01 (Interim Notice 23LB01)

Certain 2022 Model Year NX450h+

Potential Risk of Vehicle Fire

Model / Years Production Period Approximate Total Vehicles Approximate Stop Sale Dealer Inventory
2022 Model Year NX450h+ Early April 2021 – Late May 2022 1900 0

 

On July 12, 2023, Lexus filed a (Defect Information Report (DIR) with the National Highway Traffic Safety Administration (NHTSA) informing the agency of our intent to conduct a voluntary Safety Recall on 2022 Model Year NX450h+ vehicles.

 

Condition

A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire.

 

Remedy

Lexus is currently preparing the remedy for this issue.  When the remedy is available, Lexus dealers will replace the DC-DC converter with a new improved part FREE OF CHARGE. At this time, Lexus estimates the remedy can be available in the 4th quarter of 2023, but this timing is subject to change.

 

Covered Vehicles

There are approximately 1900 vehicles covered by this Safety Recall. No vehicles covered by this Safety Recall were distributed to Puerto Rico.

 

Owner Letter Mailing Date

Lexus will notify owners by early September 2023.

Lexus makes significant effort to obtain current Guest name and address information from each state through industry resources when mailing owner letters. In the event your dealership receives a notice for a vehicle that was sold prior to the Safety Recall announcement, it is the dealership’s responsibility to forward the owner letter to the Guest who purchased the vehicle.

Please note that only owners of the covered vehicles will be notified. If you are contacted by an owner who has not yet received a notification, please verify eligibility by confirming through TIS prior to performing repairs. Dealers should perform the repair as outlined in the Technical Instructions found on TIS.

 

New Vehicles in Dealership Inventory – Reminder

Lexus has not identified any new vehicles in dealership inventory that are covered by this Safety Recall. However, below is a reminder of the dealer’s obligations pertaining to Safety Recalls if there are new vehicles in dealership inventory:

Under Title 49, Section 30112 of the United States Code, a dealer cannot sell, offer for sale, or introduce or deliver for introduction in interstate commerce a new motor vehicle when it is aware that the vehicle does not comply with an applicable Federal Motor Vehicle Safety Standard or contains a defect related to motor vehicle safety.  Further, 49 Code of Federal Regulations §577.13 requires us to provide the following advisory:  It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied.

Vehicle Safety Recall completion should always be verified through TIS. We request your assistance to ensure involved vehicles are identified and not delivered prior to performing the remedy.

 

Pre-Owned Vehicles in Dealer Inventory

Lexus typically requests that dealers NOT deliver any pre-owned vehicles in dealer inventory that are covered by a Safety Recall unless the defect has been remedied. In this case, until remedy parts are available, delivery of a pre-owned vehicle is acceptable if disclosed to the Guest that the vehicle is involved in this Safety Recall and that the remedy is currently being prepared by Lexus.

Lexus expects dealers to use the attached Guest Contact and Vehicle Disclosure Form to obtain vehicle buyer information. Dealers are expected to provide a copy of the completed form, along with the most current FAQ, to the vehicle buyer. Lexus and the dealer may use this information to contact the Guest when the remedy becomes available.

Keep the completed form on file at the dealership and send a copy to quality_compliance@toyota.com. In the subject line of the email, state “Disclosure Form 23LB01” and include the VIN.

NOTE: Dealers can identify if any of their new and used inventory has any open campaigns in the Vehicle Inventory Summary available in Dealer Daily (: https://dealerdaily.lexus.com/). The Vehicle Inventory Summary may take up to 4 hours to populate information for newly launched campaigns.

 

Lexus Certified Used Vehicles

The LCertified policy prohibits the certification of any vehicle with an outstanding Safety Recall, Special Service Campaign, or Limited Service Campaign. Thus, no affected units are to be designated, sold, or delivered as a LCertified until all applicable Safety Recalls, Special Service Campaigns, and Limited Service Campaigns have been completed on that vehicle.

 

LCCS Service Loaners

Lexus requests that dealers remove all LCCS Service Loaner vehicles from service that are covered by a Safety Recall unless the defect has been remedied.

 

Guest Contacts

Guest who receive the owner letter may contact your dealership with questions regarding the letter and/or the Safety (Noncompliance) Recall. Please welcome them to your dealership and answer any questions that they may have. A Q&A is provided to assure a consistent message is communicated.

Guests with additional questions or concerns are asked to please contact the Lexus Brand Engagement Center (1-800-255-3987) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Head Unit Notifications

Head unit notifications are electronic messages that are displayed in the vehicle’s audio system screen. Guests who receive head unit notification regarding this Safety Recall are requested to schedule an appointment with their authorized dealer to have this Safety Recall completed.

When these messages are received by the vehicle’s Data Communication Module, the head unit will display a pop-up prompt stating that the vehicle has a new Safety Recall. The prompt will contain options to ‘Snooze’ or to ‘View’ the message. If a Guest chooses ‘Snooze’, the message will continue to reappear every 20 minutes until the Guest chooses ‘View’. If a Guest views and then closes the message, the message will be available in the Notification App if the Guest chooses to review it again. If the vehicle’s completion status remains incomplete for a period of 90 days from the message being viewed, the head unit may display a renotification pop-up prompt as an additional reminder to the Guest to have this Safety Recall completed.

The message will completely clear from the vehicle once the following conditions are met: The Safety Recall is completed, the dealer has filed a claim, and the claim is approved by Lexus. Then the message will be cleared at the next clearing cycle, which currently happens daily.

Guests who receive a head unit notification after having this Safety Recall completed can be advised to ignore the message. Guests with additional questions or concerns are asked to please contact the Lexus Brand Engagement Center (1-800-255-3987) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 

Salvage Title Vehicles

Every attempt should be made to complete an open Safety Recall when circumstances permit, unless noted otherwise in the Safety Recall dealer letter.

For complete details on this policy, refer to Lexus Warranty Policy 4.15, “What Is Not Covered by The Lexus New Vehicle Limited Warranty”.

 

Media Contacts

It is imperative that all media contacts (local and national) receive a consistent message. In this regard, all media contacts must be directed to Joshua Burns (469) 292-6449  in Lexus Corporate Communications. Please do not provide this number to Guests. Please provide this contact only to media.

 

Loaner Vehicle or Alternative Transportation Reimbursement Procedure

Until the vehicle is inspected and the remedy is performed, if necessary, Lexus recommends that Guests refrain from charging their vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius).  If this is not feasible for a Guest, a loaner vehicle or alternative transportation through Lexus Rent-A-CAR (LRAC) can be claimed for $55 per day.

 

Guest Reimbursement

Reimbursement consideration instructions will be included in the owner letter.

 


 SAFETY RECALL 23LA01 (Interim Notice 23LB01)

Certain 2022 Model Year NX450h+

Potential Risk of Vehicle Fire

 

Frequently Asked Questions

Original Publication Date: July 12, 2023

 

Q1: What is the condition?

A1: A component that converts electricity voltage could be damaged in manufacturing and experience a short circuit, generating excessive heat. Under certain conditions, this short circuit can generate enough heat to increase the risk of a vehicle fire.

 

Q1a: Are there any warnings when this condition occurs?

A1a: Yes, if this condition occurs on the vehicle, the hybrid vehicle may display the following warning messages :

 

Q1b:  Is there anything I can do to prevent this issue from occurring?

A1b:  Yes, until the remedy is performed, guests can reduce the potential for this condition to occur if they refrain from charging the vehicle while the ambient temperature has been below, is below, or is expected to drop below 41 degrees Fahrenheit (5 degrees Celsius).

 

Q2: What is Lexus going to do?

A2: Lexus is currently preparing the remedy for this issue.  When the remedy is available, Lexus dealers will replace the DC/DC converter FREE OF CHARGE.

 

Q3: When will the remedy become available?

A3: Lexus is currently preparing the parts and repair instructions for the remedy. At this time, Lexus estimates that the remedy can be available in the 4th quarter of 2023.

 

Q4: Which and how many vehicles are covered by this Safety Recall?A4:

There are approximately 1900 vehicles covered by this Safety Recall.

Model Name Model Year Production Period
NX450h+ 2022 Early April 2021 – Late May 2022

 

Q4a: Are there any other Lexus/Toyota/Scion vehicles covered by this Safety Recall in the U.S.?

A4a: Yes, certain 2021-2022 Rav4 Prime vehicles are also covered by this Safety Recall.

 

Q5: What if I previously paid for repairs related to this Safety Recall?

A5: Reimbursement consideration instructions will be provided in the owner letter.

 

Q6: How does Lexus obtain my mailing information?

A6: Lexus uses an industry provider who works with each state’s Department of Motor Vehicles (DMV) to receive registration or title information, based upon the DMV records. Please make sure your registration or title information is correct.

 

Q7: What if I have additional questions or concerns?

A7: Guests with additional questions or concerns are asked to please contact the Lexus Brand Engagement Center (1-800-2553987) – Monday through Friday, 8:00 am to 8:00 pm, Saturday 9:00 am to 7:00 pm Eastern Time.

 


Description of Problem:

The plug-in hybrid system of the subject vehicles includes a DC-DC converter that reduces the voltage of the electricity from the Hybrid Vehicle (HV) battery in order to charge the vehicle’s 12V battery. Contained within the DC-DC converter is an electric current rectifying module that is installed on the circuit board. Some of these modules may have been damaged during production by the supplier and could fail. Based on its design, if the module does fail, it will not fail to an open circuit, but instead a short circuit could occur. This allows current from the 12V battery to continue to flow through the module and the module will generate heat. Under certain conditions, if excessive heat is generated, components within and outside the DC-DC converter could sustain thermal damage, increasing the risk of a vehicle fire.

 

Chronology of Principal Events:

June 2021 – January 2022

In mid-June 2021, Toyota received a field report from Europe which indicated the driver had observed warning messages in the display and smoke from the rear seat while driving on the highway. An initial inspection was conducted at the dealer and damage was found to be concentrated to a plastic cooling duct on the DC-DC converter located under the rear seat.

The DC-DC converter with the cooling duct was then sent to the supplier for further investigation. As a result, the supplier found the cooling duct on the DC-DC converter had melted and an electric current rectifying module inside the DC-DC converter was consumed by thermal damage. The supplier could not determine the root cause of the failure of the DC-DC converter because of the extent of damage to the DC-DC converter. Separately, an investigation including Failure Tree Analysis (FTA) at the supplier identified that semiconductor chip failure could potentially be caused by different types of manufacturing damage. At that time, it was determined that Static Electrical Charge (SEC) in the manufacturing process had the highest potential to damage the electric current rectifying module and needed further investigation.

The supplier began duplication testing with a DC-DC converter that contained a chip with damage from over voltage and/or over current which simulated the chip damaged by SEC. As a result, the supplier found that if the chip failed, a short circuit occurred and the current from the 12V battery continued to flow into the module and the module generated excessive heat, resulting in the cooling duct melting. However, Toyota confirmed the temperature around the cooling duct could not reach the ignition point of the material of the cooling duct. Toyota also confirmed that vehicle systems continue to operate as long as the 12V battery had remaining charge and that a DTC for internal short circuit of the DC-DC converter is set and the customer receives a warning message on the informational display.

 

February-December 2022

In mid-February, Toyota received a field report from Canada which indicated that black smoke and burned plastic smells were noticed the day after plugging a vehicle into a home charger. As a result of the inspection of the vehicle, it was confirmed the right rear seat cushion had sustained fire damage and there was melting of the cooling duct and the cooling blower adjacent the DC-DC converter. Because of the new field report, Toyota conducted further investigation to reevaluate the worst case scenario of a DC-DC converter failure. Toyota rechecked its prior analysis and reconfirmed that the highest temperature that could be reached if the DC-DC converter failed was below the ignition point of the cooling duct material, and thus would not lead to a fire.

Toyota decided to continue the investigation regarding the relationship between the failure of the DC-DC converter and the fire damage of the rear seat cushion alleged in the field report from Canada since duplication testing could not produce fire damage to the rear seat cushion material.

In late-May, the design of the rectifier module was changed so that potential damage that occurs in the manufacturing process would not cause the module to fail to a short circuit. With the design change, the module will fail to an open circuit and would not allow the flow of current from the 12V battery through the module if the module had been damaged.
In mid- June, the rear seat cushion, the DC-DC converter, and the cooling blower from the Canada vehicle were sent to Toyota to support this investigation. Toyota and the supplier investigated these parts and found that the fire did not originate from the rear seat cushion (e.g., from a cigarette or match). The module within the DC-DC converter was consumed and the cooling blower had no signs of internal heat generation. As a result, Toyota could not determine the cause of the fire damage of the rear seat alleged in the field report from Canada.

The supplier conducted multiple duplication tests with various conditions that did not include a charging condition. Under those conditions, the supplier could not duplicate the fire damage and could not identify any new information from this testing that indicated the cause of the alleged fire damage to the rear seats. Therefore, Toyota again began to review the condition of the vehicle and the recovery parts.

 

January 2023-July 2023

As a result of the review, Toyota determined that testing of the vehicle was needed under charging conditions. Toyota also identified the breather plug of the recovered DC-DC converter was clogged. Because of these findings, Toyota requested that the supplier begin to build a testing bench to simulate the conditions of charging with a clogged breather plug.
The supplier found that if the vehicle is charging and the HV battery temperature is low enough to require a heater be activated, the current from a sub DC-DC converter within the charger also flowed into the module, resulting in increasing the maximum temperature of the DC-DC converter. In addition, the supplier observed that if the vehicle was charging and the breather plug was clogged, the temperature in the DC-DC converter became high enough to melt the aluminum case housing the DC-DC converter. The melting created small holes within the aluminum case allowing the excessive high temperature gas inside the DC-DC converter to escape from the holes, and allowing the cooling duct to ignite.

 

July 6, 2023

Based on the results of the above investigation, Toyota decided to conduct a voluntary safety recall campaign.
As of June 21, 2023 based on a diligent review of records, Toyota’s best engineering judgment is that there are four Toyota Field Technical Reports and two warranty claims that have been received from U.S. sources that relate or may relate to this condition and which were considered in the decision to submit this report.

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
LEXUS NX450H+ 2022
TOYOTA RAV4 PRIME 2021-2022

 


5 Associated Documents

Toyota – 23TB07 Dealer Package – July 2023

RCMN-23V478-3582.pdf 306.022KB

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Defect Notice 573 Report

RCLRPT-23V478-5744.PDF 215.449KB

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Recall Acknowledgement

RCAK-23V478-7262.pdf 646.025KB

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Toyota – 23LB01 Dealer Package – July 2023

RCMN-23V478-0900.pdf 321.13KB

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Toyota – Defect Information Report – July 2023

RMISC-23V478-0297.pdf 34.503KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V478&docType=RCL

 


 

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Bestseller No. 10
Pro Chaser 400W Power Inverters for Vehicles - DC 12v to 110v AC Car Inverter Converter, 6.2A Dual USB Charging Ports, Dual AC Adapter for Air Compressor Laptops (Red)
  • 【Pro Chaser Power Inverter Basics】: Our inverter produces 400 Watts continuous DC to AC power and 800 Watts instantons power, with dual 110V AC power sockets and 6.2A dual USB ports (3.1A each) power outlets.
  • 【Ideal for Road Trips】: Plug-in & go drawing power from Cigarette Lighter Socket Charger. The 6.2A dual USB ports can be used to charge appliances such as kindles, cellphones, iPads, tablets, cameras, air pods and etc. And the power sockets can be used to supply power to any appliances requiring 300W to 400W power such as laptops, DVD players, breast pumps, bottle warmers and etc.
  • 【Portable Design】: The compact cellphone-sized design ideal for carrying around in vehicles. The 30 inch (75 cm) cord allows the inverter to reach out long towards back seat. Ideal for road trips, camping & vacations.
  • 【Built-in Safety Protection】The built-in fuse provides full protection against short-circuit, over-load, low-voltage, over-voltage & over-temperature. The cooling fan turns on automatically when internal temperature reaches 113F (45℃), maintaining the working temperature in a cool and safe range.
  • 【Durable Metal Housing】Durable metal housing provides advanced protection from drops and bumps. Evenly colored housing with neat laser print on the surface delivers fashionable finish. 12-month Warranty.

Last update on 2024-06-25 / Affiliate links / Images from Amazon Product Advertising API

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